1969 140 drivetrain, OK, I replaced the clutch and rebuilt the gearbox. Replaced damaged syncro, new dog slides and springs, replaced layshaft. Before rebuilding the gearbox I could shift 1st, 3rd and 4th. It would grind going into second either from 1st to 2nd or down from 3rd to second. It had a damaged three gear syncro. Now, after the rebuild I can shift up in all gears, even at hot rod speeds, but cannot downshift from third to second or if in second cannot shift down to 1st. I can shift down when almost stopped. And usually if I push clutch in and give it a little gas and then shift into first. I have little free play and the clutch engages at about 3/4 way up. I have no more adjustment out on the clutch. I had the flywheel resurfaced. It is a Sachs clutch. I do not know now if it is still a gearbox or clutch problem. If I press the clutch in it disengages and revs engine at the 7/8 up pedal. I replaced the pilot bearing when I replaced the clutch. Do I need more adjustment to make up for the flywheel and new clutch? The box easily shifts through all gears when sitting.

When you measure it, how much free play do you have?

I am looking for any advice before I pull the gearbox again. The clutch is at 1/2 free play. The gearbox fluid is even with the hole. 85-90w weight oil. 100f outside. Shifts correctly when not running, up or down. When running will shift up fine 1-4. Shifts down from 4 to 3 but refuses to shift into 2. Not even a grind. I put it up on stands and ran it through the gears. Again would shift up but not down to 2 or 1 until motion is almost stopped. I learned that when it was in 2nd and running and then I shifted into neutral it would not go back into 2nd without motion stopped. Same for 1st. I need help on this. Even if I pull the box I am not sure what to look for. I have a variety of manuals. This is the first time I have tried work on a gearbox. There are a couple of things that stick in my mind. First on the rear long dog slides does the long end go towards the front or the rear(towards the 1st gear or 2nd) The sources I looked at said rear or towards 1st gear. Second:The shifting bars did not look correct. The notches on them would not line completely up with the ball bearing hole. There was not enough room for them to travel all the way to the third notch. One of the shift rods was not straight up with the fork attached. Could I have a bent fork? I would think the shaft is assemble correctly or it would not shift up while moving. No missing or extra pieces. Looked at pictures of my shaft order. Everything went together will no problems.

Why don't you ask the place that sold you the parts?

I think I may have narrowed it down. I made a longer clutch fork adjuster.



I now can make the clutch slip with too much adjustment. Even this did not fix 1st and second. I have had 3/8-1/2 free play to none and beyond and this does not change 1st and 2nd gear problem.

I now think it has something to do with the reassembly of the gearbox. The last gear that slides on may be backwards. It is under the slide gear that covers when shifting between 1st and 2nd.